Electric Generator

ABSTRACT

A simpler to manufacture electrical machine generator or motor designed to be built of 2 dimensionally cut flat stock materials with special utility as a larger than conventional diameter electric generator that is designed to operate at lower revolutions per minute than conventional generators so as to be able to be driven by human legs or arms or wind generation at low wind speeds, or water movement at low or zero water drop distance or ‘head’ or other applications.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a CIP continuation in part of U.S. Ser. No.14/479,313 6 Sep. 2014. This application claims the benefit of PPA Ser.No. 61/874,370 filed 6 Sep. 2013 by the present Inventor, which isincorporated by reference.

Disclosed as related applications and integrated into this disclosure byspecific reference to previous applications by the same inventor are:PPA Ser. No. 61/874,370 filed 6 Sep. 2013

DESCRIPTION BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

Drawings—Figures

FIG. 1. An exploded view of the Generator.

FIG. 2. An outside view of the generator.

FIG. 3. A sectional view of the generator.

FIG. 4 A detail view of the axle 1 of the generator as seen in FIG. 3.

FIG. 5 A detail view of box closure piece 7 edge of the generator a seenin FIG. 2

FIG. 6 The edge of the box side 6 without a closure piece 7 showingcastellations and slots or teeth on stator 6 stator box side edge.

FIG. 7 a side view of the generator with one stator box closure 7removed and a circle B to show the origin of the detail magnification ofFIG. 8.

FIG. 8 A detail side view of stator 6 stator box side edge includingwires stator winding wires in section with cross mark convention to showalternating electromotive voltage direction in alternate winding slotsin opposition to rotor magnets 14 of alternating magnetic polarity.

FIG. 9 A view of a rotor cut out nesting method where the pieces 2 arealso litening holes in the rotor, and may have a shared cut between twopieces with calculated kerf correction.

FIG. 10 Poles and Magnetically Conductive Box Closure piece

FIG. 11 Bent Poles and Magnetically Conductive Box Closure piece onStator

FIG. 12. Under rotor magnet piece two sided and Under rotor magnet pieceone sided

FIG. 13 Rotor and Magnets with installed Under rotor magnet pieces

DRAWINGS—REFERENCE NUMERALS

1 Shaft, Axle

2 Rotor Tooth Connect, rotor axle torsion pinned spacer or peripheralrotor spacer interlock pieces

3 Rotor

4 Spacer

5 Ball-Bearing, or other bearing

6 Stator, Box Side

7 Stator Tooth Connect, Box Closure piece

8 Interior Stator Reinforcement and bearing seat

9 Interior Stator Reinforcement and bearing seat

10 Bolt

11 Nut

12 Washer

13 Pedal

14 Magnet

15 wire zig zagged around the circumference

16 externally accessible slot for wire

17 slot of interlocking castellations

18 peripheral rotor spacer interlock pieces

19 pin

20 Magnetic Box Closure piece

21 Unbent cutout Magnet Pole Face and Riser

22 Magnetic Pole Face

23 Magnetic Pole Riser

24 Bending Slots

25 Protrusion to locate slot in cover

26 Slot in cover

27 Locating Nib

28 Number cut to show size and position assembly

29. Circumferential interlock protrusion

30. Overhanging outside entrapment

31. Under rotor magnetically conductive pieces

DESCRIPTION

The invention comprises a larger than conventional diameter electricgenerator that is designed to operate at lower revolutions per minutethan conventional generators so as to be able to be driven by human legsor arms or wind generation at low wind speeds, or water movement at lowor zero water drop distance or ‘head’ or other applications A largerdiameter and less wide low rpm generator which is designed to beconstructed by 2 dimensional cutting of flat stock materials.

Ideally the invention would be able to be capable of generatingelectricity without batteries in the system. It should generate power inthe lowest wind speeds. Rapid design variation and field modificationshould be inherent. Low Audio and RF noise is desirable. Therefore it isdesirable to avoid Slip rings which can cause sparks and there forexplosions and radio interference. Slip rings are susceptible tocorrosion and therefore susceptible to failure and require maintenance.The generator/alternator achieved will be quieter, and there for be lessdisruptive to the people working in proximity. A reduction gear or drivewill not be required, with resulting decreases in noise and efficiencylosses compared to gearboxes and chains etc.

The generators rotor must have the largest possible diameter to achieveusable voltages in the smallest of winds, and the low human pedalingspeed and low head water wheel speeds. Physical repatching of Coils isan efficient electronic control method to effectively extract energyfrom wind and other small variable generation sources. Physicalrepatching avoids voltage drops across semiconductors and parasiticpower drains in switching circuits.

Such a low rpm generator will be able to take advantage of lower windsbecause it can use the dense turbine blade disks associated with waterpumping wind generators. The low tips speeds of the wind turbines makethe wind turbine quieter.

The ability to generate usable power in the lowest winds is a differentdefinition of efficiency, in the sense of having power when you need it,without relying on heavy and expensive batteries to store energy betweenhoped for high wind episodes required by other generators.

To generate large wattages from a human for long periods of time, largeamounts of cooling are necessary, most practically by wind. The additionof a large fan for cooling the rider will increase total work output byperhaps 20 fold per session. Humans emit perhaps 80% waste heatsimilarly to a passenger car, so humans over heat if you run them hardstanding still as a passenger car does. Probably All exercise machinesshould have large user controlled fans.

Possibly the same fan that is used for the Wind Generation could beapplied as a cooling blower during doldrums where human generation maybe required.

In summary a low rpm generator has many applications, such as low speedwind of the historical water pumping turbine style and historical graingrinding “sail” style, human and animal power, low head water power suchas surface flow using a floating paddle wheel concept and wave poweredbuoys

The generator's edge shape is made up of flat or planar sections 7 ofsufficient quantity to have some circularity, that is to say as apolygon of equal sides whose junctions fall on the same circle, aregular convex equiangular polygon. This design facilitates access toopen slots for winding placement. The zig zag winding of single strandscirculating around the periphery with an air core magnetic circuit isthe primary design described here, as this is lightweight, the magnetsare permanent and the total expected power is low.

Other configurations are possible such as prewound coils that span twoopposed slot sets as 4 winding slots in total could allow a moreconventional salient or lapped pole generator/motor winding to beaccessed from the exterior.

Alternate configurations of more conventional circular windings could bebuilt around two of these deeper cuts for single phase poles or acrossmany cuts for multiphase winding schemes, wherein it is probable thatmagnetically conductive core material would be preferred to form thestator, layers of which could be stacked between the side panels in lieuor in addition to the generator box closure of drawing 13 etc, which ispresently not shown in these drawings which focus on non magneticstructural materials and air cored windings.

The box closure pieces 7 could be make of magnetically conductivematerials which could have protrusions through the center of the coilsto form poles of magnetic circuits. These closure pieces could be madeof 2d stacks of thin sheets of magnetically desirable steels to form thecap and pole protrusion utilizing a of a 2d manufacturing method.

Other designs polygonal designs with unequal sides that do not fall onthe same circle could allow the creation of shapes of footings for thegenerator, and stair cases to climb the generator, however theexternally accessed slots would become very deep and less convenient.

FIG. 1. An exploded view of the Generator.

Drawing page 10 a. At the top a drawing of circular rotor disk, one oftwo, with two examples of castellated spacers(axle torsion spacer,peripheral spacer) placed as many more would be before the second diskis placed on top and united to form the generator rotor.

FIG. 2. An outside view of the generator.

FIG. 3. A sectional view of the generator.

showing how a metal plate 8 could form a harder bearing seat materialsuch as metal when combined with a stator side made of a lighter softermaterial such as wood,

FIG. 4 A detail view of the axle 1 of the generator as seen in FIG. 3.

In the Drawing FIG. 4. sectional bisection two dimensional drawing of athe comprising a pin or spirol pin or glue or other means, shownconnecting to the axle torsion spacers thru the axle 1 or (so called“bracket” in the bicycle industry), and the castellated interconnectionwith the rotor plates are shown, and bearings that would allow thepedals to rotate the axle and the rotor to be rotated by the spirol pinand the castellated spacers which are attached to form the rotor.

Drawing page 12. A partially bisected elevation view of one side of theexternal motor frame and the pedal axle wherein the pedal axle bearingis seated on a double thickness of material around the axle area that isalso located with holes for bolt, rivets or other connection means wherethe total weight of the motor frame might be reduced from having to becut from a material that is as thick as the bearing seating area.

FIG. 5 A detail view of box closure piece 7 edge of the generator a seenin FIG. 2

FIG. 6 The edge of the box side 6 without a closure piece 7 showingcastellations and slots or teeth on stator 6 stator box side edge.

FIG. 7 a side view of the generator with one stator box closure 7removed and a circle B to show the origin of the detail magnification ofFIG. 8.

FIG. 8 A detail side view of stator 6 stator box side edge includingwires stator winding wires in section with cross mark convention to showalternating electromotive voltage direction in alternate winding slotsin opposition to rotor magnets 14 of alternating magnetic polarity.

A detail elevation of one of the flat sections of the polygonal edge ofthe generator wherein the castellations have additional deeper cut slotsin the edge down to very near the operating edge of the moving generatorrotor, these deeper cuts being placed in locations that still allow thestructural interlocking and the cuts through the castellation can beused as screw holes for closure wherein these deeper cut slots are usedto lay in zig zag conductor stator wiring from the exterior without theneed to thread through a closed hole.

FIG. 9 A view of a rotor cut out nesting method where the pieces 2 arealso litening holes in the rotor, and may have a shared cut between twopieces with calculated kerf correction wherein two castellated piecesare offset and adjacent so that they share a cutting line to form twosides at once, thus saving time on the cutting machine. The exteriorstatic frame of the machine can be litened by similar double use ofcutouts or ‘nesting’ as in this drawing. Also shown are holes forcastellated peripheral rotor spacer plates 2, whose position could becircular but may also be canted to towards 45% from the circularorientation to provide stiffness and warp resistance to the stator, atsome cost in air friction (windage) that could be translated intointentional blowing similar to a vacuum cleaner turbine if theapplication calls for such function

FIG. 10 Poles and Magnetically Conductive Box Closure pieces to improveperformance a magnetic conductive circuit by increasing magneticcontinuity, which also accomplishes reduced sound and vibration in thestator body.

A stator magnetic pole and frame circuit is fabricated in 2d from flatsheet magnetically conductive material The flat pieces of cutmagnetically conductive material which may be steel are shown where thewidth of the Magnetic Pole Face 22 is equal to the pole slot width cutin the stator to prevent lever arm teetering of the pole face andMagnetic Pole Riser 23 under the influence of the passing rotor magneticpoles.

In this example Unbent cutout Magnet Pole Face and Riser 21 cut withnumbers 28 are laid out as they would go into one flat section of themotor frame, where the Magnetic Pole Risers 23 are of different lengthsto accommodate the differing depths of the motor frame wiring slots.

Locator nibs 27 are only on one side allowing space where a sheet metalbending tool can overhang the length and perform the bending of the partwithout interference or the necessity of a custom bending tool.

Bend holes 24 form a bend line that functions without an expensive andlarge tool.

Protrusion 25 will act into slot in cover 26 in Magnetic Box Closurepiece 20.

Magnetic Box Closure piece 20 has overhanging holes 30 over stator boxside 6 castellations which can also be used on and stacked with BoxClosure piece 7 which may be of wood or other materials.

FIG. 11 shows where the Bent Poles and Magnetically Conductive BoxClosure piece on Stator interact. Shown are Circumferential interlockprotrusion 29 on magnetic and non magnetic box closure pieces, may bestacked. And overhanging outside entrapment 30 or hole of cover 6 BoxClosure 7 and Magnetic Box Closure piece 20 which may be stacked.

These designs support the wires in a raceway and prevent the wires fromsagging and catching on the rotor magnets which avoids having to stringwires tightly as would a piano and so avoids large forces resulting onthe structure. This is accomplished by Bending of the Unbent cutoutMagnet Pole Face and Riser 21 flat pole cutout sheet sized to thecorrect bend radius assisted by cutout Bending Slots 24 to a achieve aMagnetic Pole Face 22 facing the rotor magnetism, and connecting toadjacent poles by Magnetic Pole Riser 23 interlock with Slot in cover 26of Magnetic Box Closure piece 20. Height of the risers 23 is numbered 28to accommodate the varying depth of the deeper cut slots in the motorframes periphery.

FIG. 12. shows Under rotor magnetically conductive pieces 31 connectingRotor Adjacent North South Magnet Circuit sheet magnetic materialunderneath the rotor permanent magnets or electromagnets. There arebending slots 24 which accommodate the curvature of the rotor.

FIG. 13 is a view of Rotor and Magnets with installed Under rotormagnetically conductive pieces 31 within the rotor of the machine.

Nothing stated herein precludes or excludes other combinations andarrangements of the methods and mechanisms disclosed herein.

I claim:
 1. An electrical machine which is designed to be constructed by2 dimensional cutting of flat stock materials to perform as a generatoror motor comprising an external box, stator, motor frame of two sideswhich hold the axle in the center, wherein the peripheral edge is shapedas flat or planar sections of sufficient quantity to have somecircularity, that is to say as a polygon of equal sides whose junctionsfall on the same circle, a regular convex equiangular polygon, whose twosides are closed by flat closure pieces that interlock with the 2 sidesof the stator by castellations, which can be additionally structurallyconnected by various means, wherein additional deeper cut slots in thein said motorframe's periphery reach inside to very near the movingperipheral edge of the internal axle driven moving generator rotor,these deeper cuts being placed in locations that still allow thecastellated stator and flat closure pieces to be structural interlockingand said deeper cuts can be used as fastener receptacles holes for saidflat closure pieces, wherein said deeper cut slots are used to lay inzig zag conductor stator wiring from the exterior without the need tothread all the wire through closed holes, alternatively stated, as anopen wire winding access closed by a castellated cover, wherein thewindings are of said zig zag style where a single wire proceeds aroundthe entire circumference of the generator frame, where each zig wouldsee the opposite magnetic polarity of the next zag in the wire whilebeing driven by alternating north and south permanent magnets mounted onthe rotor, wherein the voltage generated in the wire by said zig or zagwould be of the same momentary voltage polarity direction due to thehand rule of magnetic flux direction being reversed as said wire zigs orzags from one side of the frame to the other side of said motor frame,wherein each wire winding which has been zig zagged around thecircumference of the motor frame 6 can be connected in series orparallel with additional wires that have also been zig zagged around thecircumference of the same motor in the same deeper slots, wherein saidmagnets are placed across opposing holes just below the edge of theperiphery of the two plates which make up the rotor sides, andcomprising, a connection between the axle and the rotor transmitting therotating forces to the rotor plates by castellated spacer plate whichdistributes the forces from the axle attachment by pin or spirol pin orglue or other means thru the spacer and into the rotor plates, andcomprising bearings that allow the rotation of the axle, said bearingsare held in place by a layering of bolted motor frame reinforcing platescut from flat stock material wherein the inner plate is serving as abearing seat and the outer plate serving as to clamp the bearings outerrace so the inner race can clamp on each side against spacer and therotor pieces, Comprising additional castellated spacer plates similar tosaid axle castellated spacer plates distributed around the rotor tomaintain the structural ridgidity of the rotor. Further comprising Polesand Magnetically Conductive Box Closure pieces wherein a stator magneticpole and frame circuit is fabricated in 2d from flat sheet magneticallyconductive material, wherein the width of the Magnetic Pole Face 22 isequal to the pole slot width cut in the stator, Wherein Unbent cutoutMagnet Pole Face and Riser 21 cut with numbers 28 where the MagneticPole Risers 23 are of different lengths to accommodate the differingdepths of the motor frame wiring slots, and Locator nibs 27 are only onone side opposite to that of the Magnetic Pole Risers 23, and Bend holes24 form a bend line, and Protrusion 25 will act into slot in cover 26 inMagnetic Box Closure piece 20 wherein Magnetic Box Closure piece 20 hasoverhanging holes 30 over stator box side 6 castellations which can alsobe stacked with Box Closure piece 7 which may be of wood or othermaterials, wherein the Circumferential interlock protrusion 29 exist onmagnetic and non magnetic box closure pieces, and may be stacked,Further comprising the Unbent cutout Magnet Pole Face and Riser 21 flatpole cutout sheet sized to the correct bend radius is assisted by cutoutBending Slots 24 bent to create a Magnetic Pole Face 22 facing the rotormagnetism, and connected to adjacent poles by Magnetic Pole Riser 23interlock with Slot in cover 26 of Magnetic Box Closure piece 20 whereinheight of the risers 23 is numbered 28 to accommodate the varying depthof the deeper cut slots in the motor frames periphery, Furthercomprising Under rotor magnetically conductive pieces 31 connectingRotor Adjacent North South Magnet Circuit sheet magnetic materialunderneath the rotor permanent magnets or electromagnets with bendingslots 24 which accommodate the curvature of the rotor.
 2. The method ofmanufacturing an electrical machine which is designed to be constructedby 2 dimensional cutting of flat stock materials to perform as agenerator or motor comprising an external box, stator, motor frame oftwo sides which hold the axle in the center, wherein the peripheral edgeis shaped as flat or planar sections of sufficient quantity to have somecircularity, that is to say as a polygon of equal sides whose junctionsfall on the same circle, a regular convex equiangular polygon, whose twosides are closed by flat closure pieces that interlock with the 2 sidesof the stator by castellations, which can be additionally structurallyconnected by various means, wherein additional deeper cut slots in thein said motorframe's periphery reach inside to very near the movingperipheral edge of the internal axle driven moving generator rotor,these deeper cuts being placed in locations that still allow thecastellated stator and flat closure pieces to be structural interlockingand said deeper cuts can be used as fastener receptacles holes for saidflat closure pieces, wherein said deeper cut slots are used to lay inzig zag conductor stator wiring from the exterior without the need tothread all the wire through closed holes, alternatively stated, as anopen wire winding access closed by a castellated cover, wherein thewindings are of said zig zag style where a single wire proceeds aroundthe entire circumference of the generator frame, where each zig wouldsee the opposite magnetic polarity of the next zag in the wire whilebeing driven by alternating north and south permanent magnets mounted onthe rotor, wherein the voltage generated in the wire by said zig or zagwould be of the same momentary voltage polarity direction due to thehand rule of magnetic flux direction being reversed as said wire zigs orzags from one side of the frame to the other side of said motor frame,wherein each wire winding which has been zig zagged around thecircumference of the motor frame 6 can be connected in series orparallel with additional wires that have also been zig zagged around thecircumference of the same motor in the same deeper slots, wherein saidmagnets are placed across opposing holes just below the edge of theperiphery of the two plates which make up the rotor sides, andcomprising, a connection between the axle and the rotor transmitting therotating forces to the rotor plates by castellated spacer plate whichdistributes the forces from the axle attachment by pin or spirol pin orglue or other means thru the spacer and into the rotor plates, andcomprising bearings that allow the rotation of the axle, said bearingsare held in place by a layering of bolted motor frame reinforcing platescut from flat stock material wherein the inner plate is serving as abearing seat and the outer plate serving as to clamp the bearings outerrace so the inner race can clamp on each side against spacer and therotor pieces, Further comprising additional castellated spacer platessimilar to said axle castellated spacer plates distributed around therotor to maintain the structural ridgity of the rotor, Furthercomprising Poles and Magnetically Conductive Box Closure pieces whereina stator magnetic pole and frame circuit is fabricated in 2d from flatsheet magnetically conductive material, wherein the width of theMagnetic Pole Face 22 is equal to the pole slot width cut in the stator,Wherein Unbent cutout Magnet Pole Face and Riser 21 cut with numbers 28where the Magnetic Pole Risers 23 are of different lengths toaccommodate the differing depths of the motor frame wiring slots, andLocator nibs 27 are only on one side opposite to that of the MagneticPole Risers 23, and Bend holes 24 form a bend line, and Protrusion 25will act into slot in cover 26 in Magnetic Box Closure piece 20 whereinMagnetic Box Closure piece 20 has overhanging holes 30 over stator boxside 6 castellations which can also be stacked with Box Closure piece 7which may be of wood or other materials, wherein the Circumferentialinterlock protrusion 29 exist on magnetic and non magnetic box closurepieces, and may be stacked, Further comprising the Unbent cutout MagnetPole Face and Riser 21 flat pole cutout sheet sized to the correct bendradius is assisted by cutout Bending Slots 24 bent to create a MagneticPole Face 22 facing the rotor magnetism, and connected to adjacent polesby Magnetic Pole Riser 23 interlock with Slot in cover 26 of MagneticBox Closure piece 20 wherein height of the risers 23 is numbered 28 toaccommodate the varying depth of the deeper cut slots in the motorframes periphery, Further comprising Under rotor magnetically conductivepieces 31 connecting Rotor Adjacent North South Magnet Circuit sheetmagnetic material underneath the rotor permanent magnets orelectromagnets with bending slots 24 which accommodate the curvature ofthe rotor.